Mobile robot with conveyor system

ABSTRACT

A mobile robot is provided for use in an operating environment. The mobile robot may include a mobile robot base, a conveyor system and a drive system. The conveyor system may be supported by the mobile robot base. The conveyor system may include a conveyor belt configured to receive an item with the mobile robot and/or provide the item from the mobile robot. The conveyor system may be configured to support the item during movement of the mobile robot within the operating environment. The drive system may be arranged with the mobile robot base. The drive system may be configured to move the mobile robot within the operating environment and position the conveyor system such that the conveyor belt is operable to receive the item with the mobile robot and/or provide the item from the mobile robot.

BACKGROUND OF THE DISCLOSURE 1. Technical Field

This disclosure relates generally to robotics and, more particularly, toa mobile robot for moving items within an operating environment.

2. Background Information

An order fulfillment center typically includes a warehouse with astorage area and a packaging area. To fulfill customer orders, itemswithin the storage area are gathered and moved to the packaging area tobe packaged and subsequently shipped to customers.

Items may be gathered and moved within an order fulfillment center invarious manners. A large fulfillment center, for example, may include asorting system for picking items from the storage area and transportingthose items to the packaging area. A sorting system may include a largenetwork of conveyors and slides. This network of conveyors and slidesmay also be paired with at least one picking machine. With such anarrangement, the picking machine picks items in the storage area anddispose those items with the conveyors and slides. The conveyors andslides subsequently transport the items to various destinations; e.g.,outputs within the packaging area. Such a sorting system, however,typically requires a large and permanent infrastructure which isexpensive to implement and maintain. Furthermore, such a sorting systemtypically is difficult to reconfigure for retrofitting.

There is a need in the art for improved methods, apparatuses and systemsfor transporting and/or sorting items between locations.

SUMMARY OF THE DISCLOSURE

Methods, apparatuses and systems are provided involving at least onemobile robot. In one embodiment, a mobile robot is provided for use inan operating environment. The mobile robot may include a mobile robotbase, a conveyor system and a drive system. The conveyor system may besupported by the mobile robot base. The conveyor system may include aconveyor belt configured to receive an item with the mobile robot and/orprovide the item from the mobile robot. The conveyor system may beconfigured to support the item during movement of the mobile robotwithin the operating environment. The drive system may be arranged withthe mobile robot base. The drive system may be configured to move themobile robot within the operating environment and position the conveyorsystem such that the conveyor belt is operable to receive the item withthe mobile robot and/or provide the item from the mobile robot.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description will be better understood when readin conjunction with the appended drawings, in which there is shown oneor more embodiments of the present disclosure. It should be understood,however, that the various embodiments of the present disclosure are notlimited to the precise arrangements and instrumentalities shown in thedrawings.

FIG. 1 is a side view diagrammatic illustration of a mobile robot.

FIG. 2 is a side view diagrammatic illustration of the mobile robotreceiving an item at a pickup location within an operating environment.

FIG. 3 is a side view diagrammatic illustration of the mobile robottransporting the item between the pickup location and a drop offlocation within the operating environment.

FIG. 4 is a side view diagrammatic illustration of the mobile robotproviding the item at the drop off location within the operatingenvironment.

FIG. 5 is a block diagram of mobile robot subsystems and a remotecomputer system in signal communication with the mobile robot.

FIG. 6 is a block diagram illustration of steerable, forward and reversemovement of the mobile robot.

FIG. 7 is a block diagram illustration of zero turn movement of themobile robot.

FIG. 8 is a block diagram illustration of omnidirectional movement ofthe mobile robot.

FIG. 9 is a top view diagrammatic illustration of the mobile robot.

FIG. 10 is another side view diagrammatic illustration of the mobilerobot.

FIG. 11 is another side view diagrammatic illustration of the mobilerobot.

FIG. 12 is a flow diagram of a method involving a mobile robot.

FIG. 13 is a block diagram of the mobile robot operating according to anembodiment of the method of FIG. 12.

FIGS. 14-17 are a side view diagrammatic illustrations of alternateembodiment mobile robots.

FIGS. 18-20 are top view diagrammatic illustrations of more alternateembodiment mobile robots.

DETAILED DESCRIPTION

FIG. 1 illustrates a mobile robot 30 configured to transport one or moreitems 32 within an operating environment 33. This mobile robot 30, asshown in FIG. 2 for example, may autonomously gather or otherwisereceive an item 32 (or items) at a pickup location 34. Referring to FIG.3, the mobile robot 30 may autonomously move the received item 32 fromthe pickup location 34 to a drop off location 36. Briefly, this item 32movement may involve moving the mobile robot 30, with which the item 32is disposed, within the operating environment 33. The item 32 movementmay also (or alternatively) involve moving the item 32 relative to themobile robot 30 utilizing a conveyor system 38, where the mobile robot30 may be stationary and/or moving within the operating environment 33.Referring to FIG. 4, the mobile robot 30 may subsequently autonomouslydeliver or otherwise provide the item 32 at the drop off location 36.Such item 32 transportation may be utilized to provide a virtual itemsorting system as described below. However, the mobile robot 30 may alsoor alternatively be configured to perform one or more tasks other thanthe foregoing exemplary transportation task.

Referring again to FIG. 1, the mobile robot 30 may be configured as anautonomous mobile robot such as, for example, an autonomous vehicle orautonomous mobile conveyor system. More particularly, this mobile robot30 may be configured to perform one or more of its tasks withoutcontinuous outside control and/or intervention. The mobile robot 30, forexample, may receive instructions to perform a certain task at a certainlocation; e.g., receive an item 32 at a pickup location 34, etc. Themobile robot 30 may subsequently determine and perform the operation(s)necessary to complete the task based on one or more factors. Suchfactors may include, but are not limited to, a current location of themobile robot 30, the location of where the task is to be performed,obstacle(s) surround the mobile robot 30, obstacle(s) between the mobilerobot 30 and the location of where the task is to be performed, the typeof operating environment in which the task is to be performed, and thetype of task to be performed. The mobile robot 30 may also be configuredto adapt to unknown, new and/or changing operating environments withoutadditional (e.g., human) outside control and/or intervention.

The mobile robot 30 may be fully autonomous during performance of one ormore of its tasks. The mobile robot 30 may also or alternatively besemi-autonomous during performance of one or more of its tasks. Themobile robot 30 may still also or alternatively be (e.g., remote)controlled by an operator (e.g., a human controller) during performanceof one or more of its tasks.

The term “fully autonomous” may be used to describe an apparatus thatperforms one or more tasks without, for example, any outside controland/or intervention. A fully autonomous mobile robot, for example, mayperform a task without receiving instructions (e.g., vectors, commands,etc.) from a human operator during performance of the task.

The term “semi-autonomous” may be used to describe an apparatus thatperforms one or more tasks without, for example, continuous outsidecontrol. A semi-autonomous mobile robot, for example, may perform a taskutilizing one or more periodic instructions from an operator (e.g., ahuman controller) that bound and/or qualify the performance of the task.The instructions may provide, for example, an updated location of wherethe task is to be performed, identify an unknown obstacle, control thescope of the task, control when the task should be performed, define howthe task should be performed, define how the task should not beperformed, etc.

FIG. 5 is a block diagram of the mobile robot 30. The mobile robot 30includes a sensor system 39, a communication system 40, a drive system41 and the conveyor system 38. The mobile robot 30 also includes acontroller 42 in signal communication (e.g., hardwired and/or wirelesslyconnected) with one or more of the other components (e.g., 38-41) of themobile robot 30. Each of the foregoing mobile robot components 38-42 isconfigured with (e.g., housed within and/or attached to) a base 44(e.g., body) of the mobile robot 30.

The sensor system 39 is adapted to survey one or more aspects of themobile robot's operating environment 33. The sensor system 39, forexample, may be used to determine the presence of, to locate, todetermine an identity of, to track and/or determine physicalcharacteristics of one or more aspects of the operating environment 33.These aspects may include, but are not limited to:

-   -   Topology of the operating environment 33 or an area thereof;    -   Structural features of and/or in the operating environment 33        such as walls, doors, ceilings, stairs, lifts, etc.; and    -   Objects in the operating environment 33 such as other entities        (e.g., individuals and/or mobile robots), storage units, items,        obstructions, etc.        The sensor system 39 may also or alternatively be adapted to        receive location data indicative of a location of the mobile        robot 30 and/or location(s) of other objects within the        operating environment 33.

The sensor system 39 includes one or more sensors 46 such as, forexample, location sensors. These sensors 46 may be operated to spatiallylocate (e.g., triangulate) the mobile robot 30 relative to, for example,its surrounding environment, its geographic location and/or one or morelocators. Examples of a locator include, but are not limited to, an RFIDtag and a physical landmark. The sensors 46 may also or alternatively beoperated to locate and/or identify other objects within the operatingenvironment 33. Examples of a sensor 46 which may be included with thesensor system 39 include, but are not limited to, a proximity sensor, aglobal position system (GPS), a radar system, an infrared system, alaser system, a radio transceiver, and a visual location system with atleast one optical camera.

The communication system 40 may be adapted to receive data from a remotecomputer 48 such as, but not limited to, a central hub. Other examplesof a remote computer 48 include, but are not limited to, a tabletcomputer, a personal computer, a laptop computer, a personal digitalassistant (PDA), a cell phone, a smart phone and a Bluetooth enableddevice. The communication system 40 may also or alternatively be adaptedto send data to a remote computer (e.g., 48); e.g., the central hub. Thecommunication system 40 of FIG. 5, for example, includes a receiver 50and a transmitter 52, which may be configured together as a transceiverin other embodiments. The receiver 50 may be a cellular, satelliteand/or radio receiver. The transmitter 52 may be a cellular, satelliteand/or radio transmitter. The communication system 40 of the presentdisclosure, of course, is not limited to the foregoing exemplaryreceiver or transmitter types of configurations.

The communication system 40 may also be adapted to communicateinformation to one or more individuals who interact with the mobilerobot 30 before, during and/or after performance of its task(s). Thecommunication system 40 of FIG. 5, for example, includes a userinterface 54.

The user interface 54 may be adapted to present information in the formof a visual message, which may include alpha-numeric characters, words(e.g., text-based instructions) and/or graphics. The user interface 54,for example, may be configured as or include a display (e.g., displayscreen or touch screen), a projector and/or a printer. The userinterface 54 may also or alternatively be adapted to present informationin the form of an audible message, which may include words (e.g., verbalinstructions) or code (e.g., a sequence of sounds, a certain tone orpitch, etc.). The user interface 54, for example, may be configured asor include an electro-acoustic transducer such as a loudspeaker. Theuser interface 54 may still also or alternatively be adapted to visuallypresent information using a marking device such as a laser pointer orother light projection device, a media (e.g., paint, ink, chalk, etc.)applicator, etc. The communication system 40 of the present disclosure,of course, is not limited to the foregoing exemplary user interface 54type or configuration.

The drive system 41 is adapted to move the mobile robot 30 within itsoperating environment 33; e.g., inside and/or outside of a building. Thedrive system 41 may enable general steerable, forward and reversemovement of the mobile robot 30 as shown in FIG. 6. The drive system 41,however, may also enable zero turn movement of the mobile robot 30 asshown in FIG. 7. “Zero turn movement” may describe movement where themobile robot 30 can turn with a zero or very close to zero turningradius; e.g., pivot substantially about a single point. In this manner,the mobile robot 30 may be a zero turn mobile robot. The drive system 41may also or alternatively enable omnidirectional movement of the mobilerobot 30 as shown in FIG. 8. “Omnidirectional movement” may describemovement where the mobile robot 30 may travel laterally (e.g.,substantially sideways or diagonally) without reorienting its body. Inthis manner, the mobile robot 30 may be an omnidirectional mobile robot.

The drive system 41 includes one or more steering and/or propulsion(“S/P”) devices 56. The drive system 41 of FIGS. 1 to 4, for example,includes a plurality of wheels 58. One or more of these wheels 58 mayeach be driven by a discrete motor. At least some of the wheels 58 mayalso or alternatively be driven by a common motor through a drivetrain.One or more of the wheels 58 may be pivoted so as to steer mobile robot30 movement. The rotational velocity of some or all of the wheels 58 mayalso or alternatively be individually controlled so as to providepropulsion and steering. The drive system 41 of the present disclosure,of course, is not limited to the foregoing exemplary wheeledconfiguration. For example, in other embodiments, the drive system 41may include a plurality of motorized (e.g., robotic and multi-linkage)track systems.

It is worth noting, the above described S/P devices 56 may be configuredand/or operated so as to provide a desired maneuverability; e.g.,steerable forward/reverse movement, zero turn movement, omnidirectionalmovement, etc. For example, zero turn movement may be enabled utilizingindependent all wheel 58 steering as well as various other techniques.Omnidirectional movement may be enabled utilizing independent all wheel58 steering as well as various other techniques. However, a body of themobile robot 30 may also or alternatively be rotatably (e.g., twistably)or otherwise mounted to the drive system 41 (e.g., via a rotatableturret) so as to provide functionality of a zero turn mobile robot or anomnidirectional mobile robot without requiring a complex drive system.For example, rather than providing all wheel steering, the body may berotated as the drive system 41 moves so as to provide functionalomnidirectional movement. The mobile robot 30 of the present disclosure,of course, is not limited to any particular devices or techniques forenabling its maneuverability.

Referring to FIGS. 1 and 9, the conveyor system 38 is supported on a topportion of the mobile robot base 44. The conveyor system 38 isconfigured to support an item 32 (or items or a quantity of media)thereon. The conveyor system 38 is also configured to carry and therebymove the item 32 (or items or the quantity of media) at least partiallyalong a longitudinal length thereof, which length extends longitudinallybetween its opposing ends 60 and 62. The conveyor system 38 of FIGS. 1and 9, for example, includes a conveyor belt 64.

The conveyor belt 64 may be configured from a single continuous hoop offlexible material; e.g., a rubber belt. The conveyor belt 64 mayalternatively be configured from a plurality of belt links, which linksare connected together into a hoop. Such belt links may be made fromflexible material (e.g., a polymer) or relatively stiff material (e.g.,metal or plastic or composite). The conveyor belt 64 may have agenerally flat and smooth support/carrying surface. Alternatively, theconveyor belt 64 may include one or more generally laterally extendingribs and/or one or more longitudinally extending rails and/or dividers.The conveyor system 38 of the present disclosure, however, is notlimited to the foregoing conveyor belt 64 types or configurations.

At least a longitudinal portion of the conveyor belt 64 and, moregenerally, the conveyor system 38 may be positioned laterally betweentwo guiderails 66. The guiderails 66 of FIGS. 1 and 9, for example, arepositioned next to and on opposing lateral sides 68 and 70 of theconveyor belt 64. Each of these guiderails 66 extends for substantiallyan entire longitudinal length of the conveyor belt 64. In this manner,the guiderails 66 may provide a barrier so as to prevent the item 32 (oritems or the quantity of media) on the conveyor belt 64 from falling offa side (e.g., 68 or 70) of the conveyor system 38 during item 32movement; e.g., rotation of the conveyor belt 64.

The conveyor system 38 may also include one or more actuators 72. Theseactuators 72 may be configured to adjust and change the position and/ororientation of at least one component (e.g., 64) of the conveyor system38. Referring to FIG. 10, for example, the actuators 72 may beconfigured to adjust the vertical height of generally the entireconveyor belt 64 (or conveying surface). Referring to FIG. 11, theactuators 72 may also or alternatively be configured to independentlyadjust the vertical height of one or more of the ends 60, 62. Theactuators 72 may thereby position one end (e.g., 62) higher than theother end (e.g., 60) to adjust and change an inclination a of theconveyor belt 64. In this manner, the conveyor system 38 of FIGS. 10 and11 can accommodate receiving items 32 from and providing items 32 todevices having different vertical heights. This may be particularlyuseful where the mobile robot 30 is being implemented as a retrofit inan existing distribution sorting environment or in a temporary sortingenvironment.

The controller 42 may be implemented with hardware, or a combination ofhardware and software. The hardware may include memory 74 and at leastone processing device 76, which may include one or more single-coreand/or multi-core processors. The hardware, of course, may also oralternatively include analog and/or digital circuitry other than thatdescribed above.

The memory 74 is configured to store software (e.g., programinstructions) for execution by the processing device 76, which softwareexecution may control and/or facilitate performance of one or moreoperations such as those described in the method(s) below. The memory 74may be a non-transitory computer readable medium. For example, thememory 74 may be configured as or include a volatile memory and/or anonvolatile memory. Non-limiting examples of a volatile memory mayinclude a random access memory (RAM) such as a dynamic random accessmemory (DRAM), a static random access memory (SRAM), a synchronousdynamic random access memory (SDRAM), a video random access memory(VRAM), etc. Non-limiting examples of a nonvolatile memory may include aread only memory (ROM), an electrically erasable programmable read-onlymemory (EEPROM), a computer hard drive, etc.

FIG. 12 is a flow diagram of a method 1200 involving a mobile robot,which may be configured similar to the mobile robot 30 described hereinand illustrated in the drawings. This method 1200 is performed totransport one or more items 32 (or a quantity or quantities of media)within an operating environment 33. However, for ease of description,the method 1200 is described below with reference to transporting asingle item 32 with the mobile robot 30 of FIGS. 1-11.

The item 32 may be configured as a packaging device. The term “packagingdevice” may describe a device that can hold, support and/or otherwisecontain one or more gaseous, liquid and/or solid materials. An exampleof a packaging device is a container such as a box, a lockbox, a crate,a canister, a bin, a pressure vessel, a tank, a suitcase, a vial or apill box. Other examples of a packaging device include, but are notlimited to, a pallet, a rack, a sack, a bag, a tube, or wrapping orpackaging material. Of course, a packaging device may have aconfiguration and type other than those described above. Furthermore,while a packaging device may take various different forms as indicatedabove, the packaging device is described and referred to below as acontainer for ease of description.

Each container may be empty. Alternatively, the container may bepartially or completely filled or loaded with one or more other items;i.e., the contents of an item 32. These contents may include varioustypes of government, business and/or consumer articles; e.g.,commodities. Alternatively, the item 32 itself may be configured as orotherwise include one or more of the government, business and/orconsumer articles. The mobile robot 30 of the present disclosure, ofcourse, is not limited to transporting the foregoing exemplary itemtypes or configurations.

The operating environment 33 may be located inside and/or outside of oneor more permanent and/or temporary structures: e.g., buildings. Themobile robot 30, for example, may perform its task(s) in an item sortingfacility. Such an item sorting facility may be located at, but is notlimited to, an order fulfillment center; a warehouse; a storagefacility; a baggage sorting facility at a transportation depot such asan airport, a railroad station or a shipping station; or a parcelsorting facility such as a postal or package service center. The mobilerobot 30 may perform its task(s) at a medical facility such as ahospital. The mobile robot 30 may perform its task(s) at a governmentand/or non-government complex, campus, compound, base and/or facility.The mobile robot 30, of course, may also or alternatively perform itstask(s) at one or more indoor and/or outdoor areas other than thosedescribed above. For example, the mobile robot 30 may perform itstask(s) onboard a vehicle such as a train, a ship, an aircraft, aspacecraft or a submersible. In another example, the mobile robot 30 mayperform its task(s) at a location which is remote from other buildings.

In step 1202, the mobile robot 30 is assigned one or more tasks. Themobile robot 30, for example, may be tasked to gather or otherwisereceive the item 32 at a pickup location 34A (see FIG. 13). The mobilerobot 30 may be tasked to move the item 32 from the pickup location 34Ato a drop off location 36C. The mobile robot 30 may also be tasked todeliver or otherwise provide the item 32 at the drop off location 36C.

One or more of the tasks may be assigned by another device such as theremote computer 48 (see FIG. 5). The mobile robot 30, for example, mayreceive assignment data from the remote computer 48 through itscommunication system 40. One or more of the tasks may also oralternatively be assigned by an individual (or individuals) through thecommunication system 40. The individual(s), for example, may select orprogram desired task assignments using the user interface 54. One ormore of the tasks may still also or alternatively be self-assigned bythe mobile robot 30. For example, where the task(s) are routine, thecontroller 42 may periodically self-assign its task(s). In anotherexample, where another mobile robot (not shown) in the operatingenvironment 33 notifies the mobile robot 30 it cannot perform anassigned task, the controller 42 may reassign the task to itself if themobile robot 30 is available and/or the task is of high priority, forexample. The method 1200 and the mobile robot 30 of the presentdisclosure, of course, are not limited to the foregoing exemplary taskassignment methodologies.

In step 1204, the mobile robot 30 moves to the pickup location 34A asshown in FIG. 13. The controller 42, for example, may signal the drivesystem 41 to autonomously move the mobile robot 30 along a predeterminedpath or an undetermined path from a starting location 78 to the pickuplocation 34A. The term “undetermined” may describe a path that isselected or created as the mobile robot 30 is moving to, for example,its destination; in the step 1204, the pickup location 34A. The pathselection or creation may be based on one or more factors: route ofshortest distance; route of shortest time; obstacles encountered alongthe way; other tasks to perform; etc.

To avoid a known or unknown obstacle (e.g., human, object or any othertype of other entity) along the path, the controller 42 may signal thedrive system 41 to slightly or dramatically divert its course around theobstacle based on data received from the sensor system 39. Thecontroller 42 may also or alternatively signal the obstacle (e.g., aremotely actuated doorway) to partially or completely move or open. Uponarriving at the pickup location 34A, the controller 42 may signal thedrive system 41 to stop and “park” the mobile robot 30 such that theconveyor system 38 may gather or otherwise receive the item 32 asdescribed below.

In step 1206, the mobile robot 30 gathers or otherwise receives the item32 as shown in FIGS. 2 and 13. For example, as described above, thecontroller 42 may signal the drive system 41 during the step 1204 tostop and “park” the mobile robot 30 such that the conveyor system 38 maygather or otherwise receive the item 32. In particular, the mobile robot30 may be parked next to a discrete, stationary conveyor system 80 atthe pickup location 34 such that the conveyor belt 64 is longitudinallyaligned with and next to a conveyor belt 82 of the stationary conveyorsystem 80. In addition, the controller 42 may signal one or more of theactuators 72 to move the conveyor system 38 such that the conveyor belts64 and 82 may be appropriately vertically orientated relative to oneanother as needed; e.g., vertically aligned.

Once the mobile robot 30 and, more particularly, the conveyor system 38is in desired item receiving position, the controller 42 may signal thestationary conveyor system 80 to move the item 32 on its conveyor belt82 towards the conveyor system 38. The controller 42 may also signal theconveyor system 38 to move its conveyor belt 64 in a manner so as toreceive the item 32 from the stationary conveyor system 80. In thismanner, the mobile robot 30 may autonomously gather the item 32 at thepickup location 34.

Of course, in alternative embodiments, the item 32 may be received usingtechniques other than that described above. For example, the item 32 maybe placed on the conveyor system 38 by another device (e.g., amanipulator arm, etc.) at the pickup location 34. This other device maybe configured discrete from the mobile robot 30, or configured with themobile robot base 44. In another example, the item 32 may be placed onor provided to the conveyor system 38 by a gravity actuated system;e.g., a slide chute for the stationary conveyor system 80. In stillanother example, the item 32 may be placed on the conveyor system 38 byan individual (e.g., a person) at the pickup location 34.

In step 1208, the mobile robot 30 moves to the drop off location 36C asshown in FIGS. 3 and 13. The controller 42, for example, may signal thedrive system 41 to autonomously move the mobile robot 30 along apredetermined path or an undetermined path from the pickup location 34Ato the drop off location 36C.

To avoid a known or unknown obstacle (e.g., human, object or any othertype of other entity) along the path, the controller 42 may signal thedrive system 41 to slightly or dramatically divert its course around theobstacle based on data received from the sensor system 39. Thecontroller 42 may also or alternatively signal the obstacle (e.g., aremotely actuated doorway) to partially or completely move or open. Uponarriving at the drop off location 36C, the controller 42 may signal thedrive system 41 to stop and “park” the mobile robot 30 such that theconveyor system 38 may deliver or otherwise provide the item 32 asdescribed below.

In step 1210, the mobile robot 30 delivers or otherwise provides theitem 32 as shown in FIGS. 4 and 13. For example, as described above, thecontroller 42 may signal the drive system 41 during the step 1208 tostop and “park” the mobile robot 30 such that the conveyor system 38 maydeliver or otherwise provide the item 32. In particular, the mobilerobot 30 may be parked next to another discrete, stationary conveyorsystem 84 at the drop off location 36 such that the conveyor belt 64 islongitudinally aligned with and next to a conveyor belt 86 of thestationary conveyor system 84. In addition, the controller 42 may signalone or more of the actuators 72 to move the conveyor system 38 such thatthe conveyor belts 64 and 86 may be appropriately vertically orientatedrelative to one another as needed; e.g., vertically aligned.

Once the mobile robot 30 and, more particularly, the conveyor system 38is in desired item provision position, the controller 42 may signal theconveyor system 38 to move the item 32 on its conveyor belt 64 towardsthe stationary conveyor system 84. The controller 42 may also signal thestationary conveyor system 84 to move its conveyor belt 86 in a mannerso as to receive the item 32 from the conveyor system 38. In thismanner, the mobile robot 30 may autonomously deliver the item 32 at thedrop off location 36.

Of course, in alternative embodiments, the item 32 may be provided usingtechniques other than that described above. For example, the item 32 maybe picked up off of the conveyor system 38 by another device (e.g., amanipulator arm, etc.) at the drop off location 36. This other devicemay be configured discrete from the mobile robot 30, or configured withthe mobile robot base 44. In another example, conveyor system 38 maymove the item 32 onto a gravity actuated system; e.g., a slide chute forthe stationary conveyor system 84. In still another example, the item 32may be picked up off of the conveyor system 38 by an individual (e.g., aperson) at the drop off location 36.

In step 1212, one or more of the foregoing method 1200 steps may berepeated in order to transport one or more additional items 32. One ormore of these items 32 may be received from the same pickup location(e.g., 34A, 34B, 34C), or one or more other pickup locations (e.g., 34Aand 34B, etc.). One or more of the items 32 may also be provided to thesame drop off location (e.g., 36A, 36B, 36C), or one or more other dropoff locations (e.g., 36A and 36B, etc.).

Using the method 1200, the mobile robot 30 may provide a virtual itemsorting system within the operating environment 33. In particular,rather than including a complex infrastructure of conveyors, ramps,slides, manipulators, or other sorting devices to provide switchablepaths between the locations, the mobile robot 30 may pick up an item 32at one of a plurality of pickup locations and subsequently deliver thatitem 32 to one of a plurality of drop off locations based on one or moreparameters. These parameters may include, but are not limited to:

-   -   A final destination for the item 32;    -   A method of shipping the item 32 from the operating environment        33 to the final destination for the item 32;    -   Type and/or configuration of the item 32 (e.g., size, weight,        geometry, fragility, etc.);    -   Item delivery priority;    -   Cost of the item 32; and    -   Contents of the item 32.        For example, the mobile robot 30 may receive two items 32 from        two different pickup locations 34. Where those items 32 are        going to the same final destination, the mobile robot 30 may        transport and deliver those items to the same drop off location        36, concurrently or sequentially. In another example, the mobile        robot 30 may receive two of the same items 32 at the same pickup        location 34. Where those items 32 are going to different final        destinations, the mobile robot 30 may transport and deliver        those items to two different drop off locations 36, concurrently        or sequentially. Of course, various combinations of the        foregoing examples are also contemplated.

In some embodiments, the method 1200 may be performed utilizing aplurality of the mobile robots 30. Each of these mobile robots 30, forexample, may be tasked to receive items 32 from a certain pickuplocation 34, but then deliver those items 32 to any one or more of thedrop off locations 36 based on the parameters associated the items 32.However, in other embodiments, each mobile robot 30 may be associatedwith a certain drop off location 36. In still other embodiments, theremay be no association between the mobile robots 30 and the pickup ordrop off locations 34 and 36.

In some embodiments, the mobile robot 30 may move laterally during theperformance of its task. For example, the mobile robot 30 may move toone of its sides without changing the orientation of its base 44. Thistype of movement may be useful in order to get close to a storage unitor an item 32. This type of movement may also be useful to move aroundtight corners, through doorways, etc. Of course, the mobile robot 30 mayalso move laterally and longitudinally concurrently in order to move ina diagonal direction.

In some embodiments, the mobile robot 30 may have a relatively smallform factor. The conveyor belt 64 and, thus, generally the conveyorsystem 38 of FIG. 1, for example, may have a lateral width of betweenabout one foot (˜1 ft) and about three feet (˜3 ft); e.g., about twofeet (˜2 ft) wide. This conveyor belt 64 and, thus, generally theconveyor system 38 may have a longitudinal length of between about twofeet (˜2 ft) and about six feet (˜6 ft); e.g., between about three tofour feet (˜3-4 ft) wide. Of course in other embodiments, the mobilerobot 30 may have a different form factor than that described above. Themobile robot 30, for example, may be smaller or larger in width and/orlength than the exemplary dimensions provided above. For example, themobile robot 30 may alternatively be configured to support and transportrelatively large items such as, but not limited to, large packingcrates, cargo modules, cargo containers (e.g., standard freight shippingcontainers), etc.

In some embodiments, referring to FIG. 1, the opposing longitudinal ends60 and 62 of the conveyor system 38 (e.g., the ends of the conveyor belt64) are substantially aligned with opposing longitudinal outermost ends88 and 90 of the mobile robot base 44. However, in other embodiments,one or more of these ends 60 and 88, 62 and 90 may be misaligned. Forexample, referring to FIG. 14, one or more of the longitudinal ends 60and 62 of the conveyor system 38 (e.g., the ends of the conveyor belt64) may each project longitudinally out from and thereby overhang arespective end 88, 90 of the mobile robot base 44. In another example,referring to FIG. 15, one or more of the longitudinal ends 60 and 62 ofthe conveyor system 38 (e.g., the ends of the conveyor belt 64) may eachbe longitudinally recessed in from a respective end 88, 90 of the mobilerobot base 44.

In some embodiments, referring to FIG. 1, the conveyor system 38 mayconsist essentially of (e.g., generally only) the conveyor belt 64 forsupporting and moving the item 32 (or items or quantity of media).However, in other embodiments, the conveyor system 38 may also includeone or more additional devices; e.g., conveyor belts. For example,referring to FIG. 16, the conveyor system 38 includes a set of twoserially arranged conveyor belts 64A and 64B. In another example,referring to FIG. 17, the conveyor system 38 includes a set of three (ormore) serially arranged conveyor belts 64A, 64C and 64B. Each of theseconveyor belts 64A-64C may have a similar configuration and operabilityas the conveyor belt 64 described above. In particular, each of theconveyor belts 64A-64C may be configured to support and move there-alongan item 32 (or items or a quantity of media). Each of the conveyor belts64A-64C may also be configured to individually or collectively adjustits vertical height and/or inclination using one or more actuators;e.g., see actuators 72 in FIGS. 10 and 11).

In some embodiments, referring to FIG. 9, the conveyor system 38 may beconfigured to receive, move and provide an item 32 all along a commondirection; e.g., along a generally straight line trajectory.

In other embodiments, the conveyor system 38 may alternatively beconfigured to receive, move and provide an item 32 along differentdirections; e.g., along a curved trajectory. For example, referring toFIG. 18, at least one of the guiderails 66 may be configured to changethe trajectory of the item 32 as it is moved by the conveyor belt 64. Inthis manner, the conveyor system 38 may receive the item 32 along afirst (e.g., generally longitudinal) direction, but provide the item 32along a second (e.g., lateral) direction, where there is an offset angledefined between the first and the second directions. This offset anglemay be approximately ninety degrees (90°) or an acute or obtuse angle.

In another example, referring to FIG. 19, the conveyor system 38 mayinclude a plurality of conveyor belts; e.g., 64A and 64B. A first ofthese conveyor belts 64A is configured to receive and move the item 32along a first (e.g., generally longitudinal) direction at one end. Asecond of the conveyor belts 64B is configured to move the item 32 alonga second (e.g., generally lateral) direction at the other end.

In still another example, referring to FIG. 20, the conveyor system 38may include at least one conveyor belt 64 configured to follow achanging (e.g., straight and then arcuate) trajectory. In this manner,the conveyor belt 64 may receive the item 32 along a first (e.g.,generally longitudinal) direction at one end. The conveyor belt 64 maythen provide the item 32 along a second (e.g., generally lateral)direction at the other end.

In still yet another example, the conveyor system 38 may be configuredwith a turntable. This turntable may be configured to change theorientation of the conveyor system 38 such that, for example, theconveyor belt 64 may receive an item 32 along a first direction butthereafter provide the item 32 along a different second directionwithout requiring movement of the mobile robot 30.

In some embodiments, the mobile robot 30 may further be configured witha manipulator system, which may be configured separate and discrete fromthe conveyor system 38. This manipulator system may include one or moremanipulators adapted to move or assist with the movement of one or moreof items. In an exemplary embodiment, each of the manipulators may beconfigured as a robotic manipulator arm.

Each manipulator atm may be electronically, hydraulically, pneumaticallyand/or mechanically actuated. Each manipulator arm may include an endeffector, which is connected to one or more arm members (e.g.,linkages). Examples of an end effector include, but are not limited to,a gripping device, a suction device, a vacuum device, an electromagnet,a winch, a clasp, the marking device, etc.

The manipulator system may also or alternatively include one or moretypes of manipulators other than those described above. For example, oneor more of the manipulators may each be configured as a pallet jack, alift platform, a slide carriage, a scissor lift or a crane.

It is worth noting, the mobile robot 30 embodiments described above maybe classified as zero infrastructure mobile robots. The term “zeroinfrastructure” may describe a mobile robot which does not require anyembedded wires, painted lines, guiderails, etc. for operation. The term“zero infrastructure” may also or alternatively describe a mobile robotwhich does not require any devices which are peripheral thereto foroperation. The present disclosure, however, is not limited to zeroinfrastructure type mobile robots. For example, the mobile robot 30 maybe configured to follow lines applied to or wires embedded within afloor. In another example, the mobile robot 30 may be configured tofollow or ride on one or more rails/tracks.

It is to be understood that the terminology used herein is used for thepurpose of describing specific embodiments, and is not intended to limitthe scope of the present disclosure. It should be noted that as usedherein, the singular form's of “a”, “an” and “the” include pluralreferences unless the context clearly dictates otherwise. In addition,unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this disclosure belongs.

Although the description above contains many specific examples, theseshould not be construed as limiting the scope of the embodiments of thepresent disclosure, but as merely providing illustrations of some of thepresently preferred embodiments of the present invention. It will beappreciated by those skilled in the art that changes could be made tothe embodiments described above without departing from the broadinventive concept thereof. It is to be understood therefore that thisdisclosure is not limited to the specific embodiments disclosed herein,but it is intended to cover modifications within the spirit and scope ofthe embodiments of the present disclosure. Accordingly, the presentinvention is not to be restricted except in light of the attached claimsand their equivalents.

What is claimed is:
 1. A method of autonomously transporting at leastone item from one location to any other location within a facility,comprising: providing a stationary conveyor system having at least afirst conveyor belt for receiving, supporting and transporting an itemfrom a first entry point in a facility to at least a second destinationpoint in the facility, the first and second points in the facility beingseparated from each other by a predetermined substantial distance;providing a stand alone fully autonomous mobile robot capable ofindependently moving to any location within the facility without theneed for any additional physical or mechanical infrastructure or guidewires having at least a second conveyor belt system having at least asecond conveyor belt, a drive system, a sensor system and a controller,the second conveyor belt system operative to be positioned by the drivesystem to a position proximate the second point in the facilityproximate to the first conveyor belt for readily accepting the at leastone item from the first conveyor belt onto the second conveyor belt andsupporting the item on the second conveyor belt, the mobile robotcapable of transporting the at least one item received by the secondconveyor belt to any location within the facility remote from the firstconveyor belt; identifying autonomously via the controller a particularitem being moved by the first conveyor belt between the first and secondpoints as well as enabling the controller to identify at least a thirdlocation from the plurality of additional locations within the facilityto which the mobile robot is to transport the particular item;positioning autonomously the second conveyor belt of the mobile robot toa position proximate to the first conveyor belt as the particular itemis approaching the second point of the first conveyor belt; advancingautonomously the first conveyor belt as well as the second conveyor beltat particular speeds and distances to enable the item to be safelytransferred from the first conveyor belt to the second conveyor belt;and transporting autonomously the item via the mobile robot to the thirdlocation.
 2. The method as defined in claim 1, including autonomouslyactivating the second conveyor belt at the third location to safelyunload the item from the second conveyor belt.
 3. The method as definedin claim 1, wherein the height of the second conveyor belt is adjustableto vertically line up with at least the first conveyor belt andincluding enabling the controller to autonomously adjust the height ofthe second conveyor belt to match the height of the first conveyor beltand enable safe transfer of the item from the first conveyor belt to thesecond conveyor belt.
 4. The method as defined in claim 1, wherein thesecond conveyor belt can accommodate at least two items at a time andincluding enabling the controller to position the second conveyor beltto accept a second item after it already has a first item thereon andfurther enabling the controller to move the robot to a first location tounload one item from the second conveyor belt and thereafter moving therobot to a second location to unload the second item from the secondconveyor belt.